Challenges with advanced batteries have cropped up with automakers, aircraft manufacturers, and laptop companies alike in recent years. One of the most notable has been thermal runaway issues with lithium-ion (Li-Ion) batteries, the most advanced battery technology now in widespread use in transportation and consumer electronics. While appropriate engineering fixes have been made to move advanced battery power forward and ensure safety, problems still occasionally occur.
The latest involves Zero Motorcycles, which is recalling certain 2013 FX electric motorcycles manufactured from January 28 through May 21 of this year, plus 2013 XU motorcycles manufactured form January 16 through May 20 of this year. According to the National Highway Transportation Safety Administration (NHTSA), a manufacturing defect with the sealant material in the battery may allow water to penetrate the battery and contact the cells.
NHTSA says this may lead to corrosion of the cells, possibly resulting in a rapid temperature increase and off-gassing of the cells’ electrolyte that may cause a burn to the rider. Zero is remedying this by replacing the battery modules in affected models free-of-charge. This follows a recall of certain 2012 model Zero electric motorcycles last year due to insufficient weatherproofing, which the agency reported may short circuit the battery management system when subjected to wet conditions and possibly cause the motorcycle to inadvertently lose power.
It should be pointed out that conventional gasoline powerplants and fuel systems have suffered their share of recalls over the decades involving cars, motorcycles, and recreational vehicles. Alternative fuel vehicles have also had the occasional challenge, such as natural gas storage issues in GM’s natural gas pickups in the early 1990s. As always, the importance is in identifying the problem, effecting an engineering remedy, and moving on.